LS-PREPOST METAL FORMING APPLICATION

TUTORIAL MANUAL

LIVERMORE SOFTWARE TECHNOLOGY CORPORATION

LS-PrePost® Metal Forming Simulation −−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−

Tutorial Manual - Forming

Version 1.0 April 2009

Copyright © 2009

LIVERMORE SOFTWARE TECHNOLOGY CORPORATION All Rights Reserved 1

LS-PREPOST METAL FORMING APPLICATION

TUTORIAL MANUAL

DISCLAIMER THE INFORMATION IN THIS TUTORIAL ARE FOR ILLUSTRATION PURPOSE ONLY AND ARE NOT INTENDED TO BE EXHAUSTIVE OR ALL-INCLUSIVE, THE LS-DYNA KEYWORD FILES PRODUCED BY LS-PREPOST MAY NOT BE EXHAUSTIVE OR APPLICABLE FOR ALL ENGINEERING PROBLEMS, LSTC ASSUMES NO LIABILITY OR RESPONSIBILITY FOR ANY INACCURACY OR DIRECT OR INDIRECT DAMAGES RESULTED FROM THE USE OF THIS DOCUMENTATION AND SOFTWARE.

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Table of Contents Tutorial #F1 – Forming of a decklid inner with line bead .......................................................................... 4 Tutorial #F2 – Forming of a cross member with physical bead ............................................................... 59

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Tutorial #F1 – Forming of a decklid inner with line bead Interface Used: Applications > Metal Forming Files required: tool.k (tool mesh) blank.nas (blank mesh) mat_decklid.k (blank material properties) bead.iges (draw bead center line) fld.fld (FLD curve) LSPP_smf_temp_cl.temp LSPP_smf_temp_dr.temp

Step 1 Note: LS-PrePost 2.4 dated April 14th, 2009 and later must be used for this tutorial. This tutorial focuses on the set-up process of a metal forming analysis using the Explicit Dynamic method within the Metal Forming interface. All components have been meshed previously. 1. Load meshed parts and open Metal Forming Interface launch LS-PrePost File → Open → LS-Dyna Keyword open “tool.k” File → Import → LS-Dyna Keyword open “blank.k”; select ‘Import Offset’ option File → Open → IGES File open ‘bead.iges’ Shown in Figure 1 are all necessary components and their relative positions. Application → Metal Forming

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Figure 1

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Step 2 2. Job Setup (refer to Figures 2 and 3) click Job Setup in the side panel in Figure 2 (launches the Job Setup Dialog in Figure 3) enter Project Name: decklid specify Master Folder set Units: L:Millimeter, F:Newton select Process Type: click: Apply

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Figure 2

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5 6 Figure 3

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Step 3 3. Define Blank (refer to Figures 4 and 5) click Blank in the side panel in Figure 4 (launches Blank Assignment Dialog in Figure 5) select “5 Blank” from the right hand list click select Element Formulation: 2-Belytschko-Tsay enter Number of Integration: 5 enter Thickness: 0.9; must hit a carriage return. click MD (launches Material Database Dialog shown in Figure 6)

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Figure 4

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Step 4 4. Load material property for the blank (refer to Figure 6) click to go to current working directory (Figure 6) click “mat_decklid.k” click Preview click OK click Done (Figure 5)

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Figure 6 10

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Step 5 5. Define Die (refer to Figures 7 and 8) Click Tool in the side panel (launches Tool Assignment Dialog in Figure 8) select the Die tab set Friction: 0.125, hit a carriage return select ‘4 Die’ from the right hand list (All part list) click keep Tool Position vs. Blank as: set Draw Direction: activate enter: 0.99 set:

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Figure 7

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Figure 8

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Step 6 6. Define Punch (refer to Figure 9) select the Punch tab enter Friction: 0.125; hit a carriage return select “1 Punch” from the right hand list (All part list) click select Tool Position vs. Blank: deactivate:  Contact Offset set Draw Direction: set:

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Figure 9 13

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Step 7 7. Define Binder (refer to Figure 10) select the Binder tab enter Friction: 0.0 select “3 Binder” from the right hand list (All part list) click select Tool Position vs. Blank: deactivate:  Contact Offset set Direction: set: click Done

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Step 8 8. Position components (refer to Figures 11, 12 and 13) click Position in the side panel in Figure 11 (launches Tool Positioning Dialog in Figure 12) activate  Blank as a movable tool activate  Die as a movable tool activate  Binder as a movable tool click Auto Position set Punch Manual Move distance: 20 click click Done Shown in Figure 13 is the properly positioned forming system

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Figure 11

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Step 9 9. Define Draw beads (refer to Figures 14 through 24) click Drawbead in the side panel in Figure 14 (launches Drawbead Dialog box in Figure 15) set RF: 288 (N/mm2) in Figure 15; (Restraining Force ‘RF’ = tensile x blank thickness x 1.2) set Force: 0.55 (RF scale factor) activate  CLabel click Pick Curve select Area (Figure 16) click Top view drag cursor with left mouse button to include curves with two rectangular boxes as shown (Figure 17) (or, alternatively, highlight curves #1, #2, #7, #8, #17 to #24, #27, #28 in the curves list box) click right mouse button to return to Drawbead Dialog click New (Figure 18) to make these curves just picked in the areas as draw beads click Pick Curve again (Figure 19) select Area (Figure 20) click Top view drag cursor with left mouse button to include curves with two rectangular boxes as shown (Figure 21) (or, alternatively, highlight curves #3, #4, #6, #9 to #16, #25, #26 in the curves list box) click right mouse button to return to Drawbead Dialog change Force to 0.50 (Figure 22) click New to make these curves just picked in the areas as draw beads highlight all beads in the left hand side box (Figure 23) select Attach to: Binder activate  Show Drawbeads click Project click Done Shown in Figure 24 is a local view of the beads projected onto the binder.

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Figure 14

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Figure 17 20

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Figure 18 21

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Figure 21

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Figure 22 24

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binder

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Figure 23 25

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Figure 24

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Step 10 10. Define Process (refer to Figures 25 through 27) click Process in the side panel in Figure 25 (launches Metal Forming Process Dialog box as shown in Figure 26) select Process Type: Forming (Figure 26) activate Active Tool:  Die select Die Action: Closure with select Die Closure With: Binder set Binder Velocity: v=1000 (mm/s) activate Active Tool:  Punch select Punch Action: Stationary activate Active Tool:  Binder select Binder Action: Stationary click Control Tab (Figure 27) activate  Adaptive set Adaptive Cycles: 20 set Adaptive Level: 2 set minimum element size Minsize: 1.5 set Output States#: 8

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Figure 25

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Step 11 11. Define Process – continued (refer to Figures 28 through 30) click Drawing Tab (Figure 28) activate Active Tool:  Die select Die Action: Closure with select Die Closure With: Punch set Punch Velocity: v=5000 (mm/s) activate Active Tool:  Punch select Punch Action: Stationary activate Active Tool:  Binder select Binder Action: follow as set binder to follow: Die click Control Tab (Figure 29) activate  Adaptive set Adaptive Cycles: 30 set Adaptive Level: 3 (finer if more accurate results are desired) set minimum element size Minsize: 1.5 set Output States#: 10 click Preview for tool kinematic animation click

or

or

to animate tools (Figure 30)

click Done click Output Dyna in Figure 29 (launches Dyna Input Decks Forming Dialog in Figure 31)

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Figure 28

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Figure 29

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Step 12 12. Define Output Options (Figures 31 and 32) click Advanced (Figure 31) set Blank File name: blank.k (Figure 32); hit a carriage return. Set Tooling File name: tools.k; hit a carriage return. Set Drawbead File name: beads.k; hit a carriage return. Set Dyna Input File name: sim.dyn; hit a carriage return. deactivate:  Dbead_As_Beam activate:  Dbead_As_Box click Templates tab

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Figure 31

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Figure 32

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Step 13 13. Define Closing and Drawing Templates (Figures 33 through 38) click Closing Tab (Figure 33) click Load browse to the working folder and select: LSPP_smf_temp_cl.temp (Figure 34) click Drawing Tab (Figure 35) click Load (Figure 36) browse to the working folder and select: LSPP_smf_temp_dr.temp (Figure 37) click Done (Figure 38)

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Figure 33 35

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Figure 34

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Figure 35 36

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Figure 36

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Figure 37

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Figure 38 38

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Step 14 14. Output LS-Dyna input decks (Figures 39) In Dyna Input Decks (Forming) Dialog click Browse to specify a file folder for output files click Output Dyna

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Figure 39

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Step 15 15. Run LS-DYNA and processing results Run LS-DYNA - C:\LSDYNA\program\ls971_s_R4.2_win32_p.exe i=sim.dyn ncpu=2 memory=200M The simulation takes about 1.5 hours on a Xeon CPU 5150 @ 2.66GHz. The actual memory used was around 57 MW (million words), about 228 MB (megabytes). Launch LS-PrePost File → Open → LS-Dyna Binary Plot Open “d3plot” 1) 3-D breakdown animation select desired parts by clicking on SelPar as shown in Figure 40 click

to animate the forming process as shown in Figure 41

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Figure 40

Figure 41 40

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2) 2-D section animation click click

(Figure 42)

click click on the node location as shown in Figure 43 click in Figure 42 click click click right mouse button and then left mouse button on

, Figure 44

set to: 180 hit a carriage return click click

to animate the 2-D section; Sections shown in Figure 45.

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Figure 43

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Figure 44

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Figure 45 43

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3) Thickness variation contour click

(Figure 46)

click click Shell Thickness click click set Min: 0.72 set Max: 0.9 set Levels: 20 click

to move to the last state

Shown in Figure 47 is the blank thickness variation contour

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Figure 47

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4) Mean stress contour click

(Figure 48)

click click Pressure select

for shell mid-plane

click click set Levels: 5 click

to move to the last state

Shown in Figure 49 is the mean stress contour at blank mid-plane.

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Figure 48

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Figure 49

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5) Formability plot click

(Figure 50)

click click select FLD file: fld_true.fld highlight file: fld_true.fld click deactivate

since FLD curve data provided is in true strain space

activate set click set set select

0.2 (Figure 51) 0.672 again (Figure 50)

shown in Figure 52 is the Formability plot of the blank activate click and drag the left mouse button to include the entire blank click shown in Figure 53 is the entire blank elements plotted onto the FLD chart.

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Figure 52 52

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Figure 53

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6) In-plane major/minor strain vector plot click

, Figure 54

highlight: S5 click click select activate key in SF: 0.02 activate pick anywhere on the blank shown in Figure 55 is the in-plane major/minor strain vector plot.

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Figure 54 55

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Figure 55

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7) Mass increase plot click

, Figure 56

highlight: glstat click select: 18-% Mass Increase click shown in Figure 57 is the mass increase of the blank in percentage.

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Figure 56

Figure 57

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Tutorial #F2 – Forming of a cross member with physical bead Interface Used: Applications > Metal Forming Files required: tool.k (tool mesh) blank.k (blank mesh) mat_xmbr.k (blank material properties) flc.fld (FLD curve)

Step 1 Note: LS-PrePost 2.4 dated April 14th, 2009 and later must be used for this tutorial. This tutorial focuses on the set-up process of a metal forming analysis using the Explicit Dynamic method within the Metal Forming interface. All components have been meshed previously. 1. Load meshed parts and open Metal Forming Interface launch LS-PrePost File → Open → LS-Dyna Keyword open “tool.k” File → Import → LS-Dyna Keyword open “blank.k”; select ‘Import Offset’ option Shown in Figure 1 are all necessary components and their relative positions. Application → Metal Forming

Figure 1 59

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Step 2 2. Job Setup (refer to Figures 2 and 3) click Job Setup in the side panel in Figure 2 (launches the Job Setup Dialog in Figure 3) enter Project Name: xmbr specify Master Folder set Units: L:Millimeter, F:Newton select Process Type: click Apply

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Figure 2

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5 6 Figure 3

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Step 3 3. Define Blank (refer to Figures 4 and 5) click Blank in the side panel in Figure 4 (launches Blank Assignment Dialog in Figure 5) select “16 Blank” from the right hand list click click Yes to LSPP question (pop-up window) of whether to convert SPCs on the blank to MF GUI select Element Formulation: 2-Belytschko-Tsay enter Number of Integration: 5 enter Thickness: 1.6; must hit a carriage return. click MD (launches Material Database Dialog shown in Figure 6)

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Figure 4

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Figure 5 63

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Step 4 4. Load material property for the blank (refer to Figure 6) click

to go to current working directory (Figure 6)

click “mat_xmbr.k” click Preview click OK click Done (Figure 5)

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Figure 6 64

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Step 5 5. Specify/accept boundary conditions for Blank (refer to Figure 7) click Symmetry Constraint tab (Figure 7) highlight: 1 XOZ[010101] (cid:0) click Show and Modify click right mouse button to return to Blank Assignment Dialog click Done

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Figure 7 65

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Step 6 6. Define Die (refer to Figures 8 and 9) Click Tool in the side panel in Figure 8 (launches Tool Assignment Dialog in Figure 9) select the Die tab set Friction: 0.125, hit a carriage return select ‘3 Die’ from the right hand list (All part list) click keep Tool Position vs. Blank as: deactivate set Draw Direction: set:

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Figure 8

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Figure 9

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Step 7 7. Define Punch (refer to Figure 10) select the Punch tab enter Friction: 0.125; hit a carriage return select “2 Punch” from the right hand list (All part list) click select Tool Position vs. Blank: deactivate: set Draw Direction: set:

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Step 8 8. Define Binder (refer to Figure 11) select the Binder tab enter Friction: 0.125 select “4 Binder” from the right hand list (All part list) click select Tool Position vs. Blank: deactivate: set Draw Direction: set: click Done

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Step 9 9. Position components (refer to Figures 12 through 14) click Position in the side panel in Figure 12 (launches Tool Positioning Dialog in Figure 13) activate  Blank as a movable tool activate  Die as a movable tool activate  Binder as a movable tool click Auto Position click Done Shown in Figure 14 is the properly positioned forming system.

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Figure 12

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Figure 14

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Step 10 10. Define Process (refer to Figures 15 through 17) click Process in the side panel in Figure 15 (launches Metal Forming Process Dialog box as shown in Figure 16) select Process Type: Forming (Figure 16) activate Active Tool:  Die select Die Action: Closure with select Die Closure With: Binder set Binder Velocity: v=1000 (mm/s) activate Active Tool:  Punch select Punch Action: Stationary activate Active Tool:  Binder select Binder Action: Stationary click Advanced (launches Advanced Setting Dialog in Figure 17) set Tool Closure Clearance: 0.1 (mm) click Done click Control Tab (Figure 18) activate  Adaptive set Adaptive Cycles: 20 set Adaptive Level: 4 set minimum element size Minsize: 1.5 set Output States#: 8

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Step 11 11. Define Process – continued (refer to Figures 19 through 21) click Drawing Tab (Figure 19) activate Active Tool:  Die select Die Action: Closure with select Die Closure With: Punch set Punch Velocity: v=5000 (mm/s) activate Active Tool:  Punch select Punch Action: Stationary activate Active Tool:  Binder select Binder Action: follow as set binder to follow: Die click Advanced (launches Advanced Setting Dialog in Figure 20) set Tool Closure Clearance: 0.1 (mm) click Done click Control Tab (Figure 21) activate  Adaptive set Adaptive Cycles: 80 set Adaptive Level: 5 set minimum element size Minsize: 1.5 set Output States#: 10 click Preview for tool kinematic animation click

or

or

to animate tools (Figure 22)

click Done click Output Dyna in Figure 21 (launches Dyna Input Decks Forming Dialog in Figure 23)

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Figure 19

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Figure 22 79

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Step 12 12. Define Output Options (Figures 23 and 24) click Advanced (Figure 23) set Blank File name: blank.k (Figure 24); hit a carriage return. set Tooling File name: tools.k; hit a carriage return. set Drawbead File name: beads.k; hit a carriage return. set Dyna Input File name: sim.dyn; hit a carriage return. click Done

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Figure 23

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Figure 24

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Step 13 13. Output LS-Dyna input decks (Figures 25) In Dyna Input Decks (Forming) Dialog click Browse to specify a file folder for output files click Output Dyna

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Figure 25

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Step 14 14. Run LS-DYNA and processing results Run LS-DYNA - C:\LSDYNA\program\ls971_s_R4.2_win32_p.exe i=sim.dyn ncpu=2 memory=240M The simulation takes about 3.0 hours on a Xeon CPU 5150 @ 2.66GHz. The actual memory used was around 82 MW (million words), about 328 MB (megabytes). Launch LS-PrePost File → Open → LS-Dyna Binary Plot Open “d3plot” 1) 3-D breakdown animation select desired parts by clicking on SelPar as shown in Figure 26 click

to animate the forming process

2 3 1 Figure 26

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2) 2-D section animation click

(Figure 27)

click click click on the node location as shown in Figure 28 click

in Figure 27

click click click

to animate the 2-D section in Figure 29

Shown in Figure 30 are a few sections throughout the animation.

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Figure 29

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Figure 30 86

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3) Thickness variation contour click

(Figure 31)

click click Shell Thickness click click set Min: 1.344 set Max: 1.6 set Levels: 16 click

to move to the last state

Shown in Figure 32 is the blank thickness variation contour

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Figure 32

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4) Mean stress contour click

(Figure 33)

click click Pressure select

for shell mid-plane

click click set Levels: 14 click

to move to the last state

Shown in Figure 34 is the mean stress contour at blank mid-plane.

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Figure 33

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Figure 34

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5) Formability plot click

(Figure 35)

click click select FLD file: fld_true.fld highlight file: fld_true.fld click deactivate

since FLD curve data provided is in true strain space

activate set click set set select

0.16 (Figure 36) 0.864 again (Figure 35)

shown in Figure 37 is the Formability plot of the blank activate click and drag the left mouse button to include an area of the blank as shown in Figure 37 click shown in Figure 38 is FLD diagram plot for the blank elements selected.

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6) In-plane major/minor strain vector plot click

, Figure 39

highlight: S16 click click select activate key in SF: 0.06 activate pick anywhere on the blank shown in Figure 40 is the in-plane major/minor strain vector plot.

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Figure 39 98

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Figure 40

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7) Major/Minor strain contour plot click

, Figure 41

click highlight: upper_eps1 shown in Figure 42 is the upper surface major in-plane strain contour highlight: upper_eps2 (Figure 41) shown in Figure 43 is the upper surface minor in-plane strain contour

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3 4

2

Figure 41

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Figure 42

Figure 43 102

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9) Thinning along a section (XY plot) click

, Figure 44

click highlight: % thickness reduction click click pick on a node along the symmetric plane, as shown in Figure 45 click

, Figure 44

click click click shown in Figure 46 is thinning percentage of the blank along the symmetric plane.

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1

3 5

2

7 10

8

9

Figure 44

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6

Figure 45

Figure 46 105

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9) Mass increase plot click

, Figure 47

highlight: glstat click select: 18-% Mass Increase click shown in Figure 48 is the mass increase of the blank in percentage.

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3

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5

4

Figure 47

Figure 48

107